Constant current control systems and methods

ABSTRACT

Systems and methods for providing a constant current controller for use in constant current welding applications are described. In one embodiment, a current controller controls the output current of the welding torch without directly measuring the output current of the welding torch. The current controller controls or sets a current in a primary winding of a transformer in an inverter of a welding power supply to control the output current of the welding torch.

RELATED APPLICATIONS/INCORPORATION BY REFERENCE

The present application claims priority to and benefit from U.S.Application No. 62/274,117, filed Dec. 31, 2015, and U.S. ApplicationNo. 62/286,764, filed Jan. 25, 2016. The above-identified applicationsare hereby incorporated by reference herein in their entirety.

BACKGROUND

Power supplies used in welding typically convert alternating current(AC) power from a wall outlet to an output that is suitable for weldingoperations. The output power can be provided at a constant outputcurrent between the welding torch and a workpiece that can be controlledby directly measuring the output current of the welding torch, forexample, at the contact tip or electrode of the welding torch.

Since the output current at the contact tip of the welding torch can bequite large during a welding operation, the current sensor used todirectly measure the output current is typically a very expensive devicesuch as a high current Hall Effect current sensor or a resistive shuntdevice. Such devices can be very expensive since they need to measurevery high weld currents and need to be fairly accurate.

Further, such devices tend to be quite large such that they cannot bemounted on a printed circuit board assembly. Accordingly, additionalcables are employed, thereby further adding to the cost burden for thistype of architecture.

What is needed is circuitry that can control the output current of thewelding torch without directly measuring the output current of thewelding torch.

BRIEF SUMMARY

Methods and systems are provided for a constant current controller foruse in welding applications substantially as illustrated by and/ordescribed in connection with at least one of the figures, as set forthmore completely in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an embodiment of a power supply in a welding systemaccording to the present disclosure.

FIG. 2 shows an embodiment of some components of a power supply systemwith a current control circuit according to the present disclosure.

FIG. 3 shows an embodiment of interleaved inverter arrangement and acurrent control circuit according to the present disclosure.

FIG. 4 shows an embodiment of a current control circuit according to thepresent disclosure.

DETAILED DESCRIPTION

Some embodiments of the present disclosure relate to systems and methodsfor providing a constant current controller for use in weldingapplications.

Some embodiments of the present disclosure provide a welding powersupply that operates in a constant current process (e.g., stick welding,gas tungsten arc welding (GTAW), tungsten inert gas (TIG) welding,plasma cutting, etc.) in which there is no direct feedback of the outputcurrent at the electrode of the welding torch. The current control isachieved by measuring a main transformer primary current, which issubstantially less than the output current at the welding torchelectrode, and using the transformer primary current to control the weldoutput current. One advantage to this type of control is that anexpensive high current sensing device (e.g., a high current Hall Effectcurrent sensor) is no longer needed to control output current so theoverall system cost is reduced. A further advantage is that thecircuitry used to control the output current, unlike the direct currentmeasurement arrangement, can be adapted for mounting on a printedcircuit board assembly.

FIG. 1 shows an embodiment of welding power supply 10 that powers,controls, and provides a constant current welding process according tothe present disclosure. The side of the power supply 10 that faces theoperator includes a control panel 12, through which the operator cancontrol the supply of, for example, one or more the following: power,weld voltage, gas flow, wire feed, weld current, etc. to a welding torch14. A work lead clamp 16 connects to a workpiece to close the circuitbetween the torch 14, the workpiece, and the power supply 10, and toensure proper current. In some embodiments, such as for stick weldingoperations, the torch 14 can include, for example, an electrode and/oran electrode holder. The portability of the power supply 10 can beenhanced by a set of wheels 18, which enable the operator to move thepower supply 10 to the location of the welding operation. Internalcomponents of the power supply 10 can be configured to convert powerfrom a wall outlet or other source of AC or direct current (DC) voltage,such as a generator, battery or other source of power, to an outputconsistent with the voltage, current, and/or power requirements of awelding arc maintained between the workpiece and the welding torch 14.In some embodiments, the power supply 10 is configured to maintain aconstant current between the torch 14 and the workpiece during thewelding operation.

In some embodiments, the power supply 10 can be configured to controlthe output current of the welding torch 14 without directly sensing theoutput current, which can be very costly in view of the high currentrequirements of most welding operations. For example, a costly currentsensor for directly measuring the output current of the welding torch 14can be a high current, Hall Effect current sensor. Instead of using acostly current sensor for directly measuring the output current of thewelding torch 14, the power supply 10 can be configured to directlymeasure the output voltage of the welding torch 14. The output voltageof the welding torch 14 is relatively small and voltage sensors used todirectly measure such output voltages are relatively inexpensive. Thepower supply 10 can be configured to use the directly measured outputvoltage of the welding torch 14 to control the output current and/or tomaintain a constant output current, for example.

In some embodiments, the power supply 10 can be further configured tomeasure and/or compare a current in a primary winding of a transformerbefore the current is transformed in a secondary winding of thetransformer into the high output current of the welding torch 14. Thecurrent in the primary winding of the transformer is relatively smalland thus does not require costly high current sensors for measurementsand/or comparisons. The power supply 10 can be configured to use themeasured output voltage of the welding torch 14 and the measured and/orcompared current in the primary winding of the transformer to controlthe output current and/or to maintain a constant output current, forexample, of the welding torch 14.

In some embodiments, the power supply 10 is inverter-based and includesone or more inverters for producing the output current (e.g., weldoutput current) of the welding torch 14. In some embodiments, the powersupply 10 is configured with interleaved two (or more) interleavedinverters. With this topology, output current control can be implementedusing a type of primary peak current mode control. However, thistopology does not employ a current sensing element on the system outputto control and regulate the constant current process.

In some embodiments, the ripple frequency seen on the output is twicethat of the fundamental switching frequency of the inverters. To controlthe output current, the switching frequency of the power source canreduced. The switching frequency can be reduced by disabling one of theinverters during the short circuit condition. When one inverter isdisabled, the output frequency is the same as the fundamental frequencyof each of the inverters or half the original frequency (i.e., thefrequency when both inverters are enabled in this example). Thisreduction in output ripple frequency limits the current (and heat) beingdelivered to the workpiece.

By employing the interleaved inverter arrangement in the power supply10, some embodiments avoid circuit complexity without a loss in responsetime. For example, by using the interleaved inverter arrangement, someembodiments can avoid additional circuitry that would continuously slewthe frequency through a time dependent control loop. In contrast, byusing the interleaved inverter arrangement, some embodiments can changethe output frequency (e.g., by double or by half) almost instantly byenabling or disabling one of the inverters, for example, via switches inthe inverters. The switches can be controlled (e.g., turned off or on)by sensors that detect, for example, a short circuit condition or anormal operating condition during a welding operation. Further, by usingthe interleaved inverter arrangement, some embodiments provide that thefundamental frequency of any of the interleaved inverter circuits doesnot change. This is different from the more complicated circuit in whichthe fundamental frequency of an inverter circuit is changed by afrequency control loop.

In some embodiments, by using the interleaved inverter arrangement,welder current can be controlled, for example, into a short circuitcondition (e.g., a TIG lift start). The interleaved inverter arrangementcan limit the energy that is provided into the short circuit so as notto melt and/or fuse the tungsten (or other material) and the basematerial together, thereby causing “sticky” starts.

Further advantages and details concerning the use of interleavedinverters in the power supply 10 can be found in U.S. Application No.62/274,117, filed Dec. 31, 2015, and U.S. Application No. 62/286,764,filed Jan. 25, 2016, which are hereby incorporated by reference hereinin their entirety.

FIG. 2 illustrates an exemplary block diagram of some components thatare part of the power supply 10 (e.g., a welding power supply) accordingto an embodiment of the present disclosure. Referring to FIG. 2, avoltage or current source 20 is configured to provide a DC current orvoltage to a first inverter circuit 24 and a second inverter circuit 26.In some embodiments, the voltage or current source 20 may be a DC sourceincluding one or more batteries. In some embodiments, the voltage orcurrent source 20 can include a circuit that rectifies an incoming ACvoltage or current and converts it into a DC voltage or current.

In some embodiments, the first inverter circuit 24 and the secondinverter circuit 26 can be configured in a parallel arrangement or aninterleaved arrangement. On one side, the first inverter circuit 24, thesecond inverter circuit 26, and the voltage or current source 20 areconnected to a first electrical circuit node 21. On the other side, thefirst inverter circuit 24, the second inverter circuit 26, and thefilter inductor 28 are connected to a second electrical circuit node 23.

FIG. 2 also shows a control circuit 90 according to an embodiment of thepresent disclosure. Although shown in FIG. 2 as two control circuits 90,the control circuit 90 can be more or less than two control circuits 90.Control circuit 90 is configured to receive voltage feedback from theoutput electrical node 25 and/or from one or more of the inverters 24,26. The control circuit 90 is also configured to measure the voltagefeedback and to measure and/or compare a current in one or more primarywindings of the one or more transformers of the one or more inverters24, 26. Further, the control circuit 90 is configured to determine orcalculate and to generate a reference current that is used to set orcontrol the current in the one or more primary windings of the one ormore transformers of the one or more inverters 24, 26. The determined orcalculated reference current can be based on, for example, a feedbackvoltage from the output of the welding torch 14 and/or a current commandsignal. By setting or controlling the current in the one or more primarywindings of the one or more transformers of the one or more inverters24, 26, the control circuit 90 controls (e.g., sets) the output currentcoming out of the transformers, the inverters 24, 26, and the weldingtorch 14.

The inverter circuits 24, 26 operate to combine their respective outputsat a single node, which feeds into a filter inductor 28 that supplies anoutput voltage V_out and/or an output current I_out for the weldingoperation. By disabling one of the inverter circuits 24, 26, the outputcurrent I_out can be reduced in frequency by half. The welding arc 32 issupplied with a welding current 30 and is connected to workpiece 34. Insome embodiments, individual inductors may be utilized in place of thefilter inductor 28. In other embodiments, the inductor 28 may havemultiple windings used to combine the outputs of the two invertercircuits 24, 26.

In operation, the control circuit 90 measures (e.g., directly measures)the voltage at the output of the welding torch 14 (e.g., electricalcircuit node 25). Based on at least the measured output voltage, thecontrol circuit 90 determines or calculates and generates a referencecurrent.

Some embodiments determine or calculate a reference current that isbased on a multi-variable transfer function that can translate acommanded primary transformer current (e.g., a commanded current in aprimary winding of a transformer in an inverter of a welding powersupply) to regulate the output current of the welding system. By usingthe transfer function, the secondary output current (e.g., a current inthe second winding of the transformer in an inverter of a welding powersupply) or the welding system output current does not have be monitoredto control the output current for the welding power supply or thewelding system.

The current from a primary winding of a transformer of the inverter 24,26 is measured (e.g., by a current sensor) and compared with thereference current. The control circuit 90 uses the comparison to controlor set the current in the primary winding, thereby controlling orsetting the current in the secondary winding of the transformer of theinverter 24, 26, the output current of the inverter 24, 26, and theoutput current of the welding torch 14 (e.g., the welding current). Insome embodiments, the control circuit 90 uses the comparison to controla switch that can turn the inverter 24, 26 on or off.

FIG. 3 is a circuit diagram illustrating an embodiment of theinterleaved inverter and control circuitry in the welding power supply10 that includes, for example, a first inverter circuit 24 (e.g., afirst forward inverter circuit), a second inverter circuit 26 (e.g., asecond forward inverter circuit), and the control circuit 90 accordingto the present disclosure. The voltage or current supply 20 isconfigured to provide DC voltage or current to the first convertercircuit 24 and the second converter circuit 26.

In the first inverter circuit 24, a pair of switches Z1, Z2 (e.g., powersemiconductor switches) chops the DC voltage and supplies it to atransformer T on the side of a primary winding of the transformer T(left side of transformer T in FIG. 3). The transformer T transforms thechopped primary voltage to a secondary voltage, at a level suitable fora cutting or welding arc, and supplies it to a secondary winding of thetransformer T (right side of transformer T in FIG. 3). The secondaryvoltage is then rectified by rectifier diodes D3, D4 and supplied to thefilter inductor 28. A set of diodes D1, D2 provides a free-wheeling pathfor the magnetizing current stored in the transformer T to flow when thepair of switches Z1, Z2 turns off, and thus resets the magnetic flux orenergy stored in the transformer core. Further, when switches Z1, Z2 areturned off, the first inverter circuit 24 is disabled and the firstinverter circuit 24 no longer contributes to the output current throughthe filter inductor 28.

Similarly, in the second inverter circuit 26, a pair of switches Z1′,Z2′ (e.g., power semiconductor switches) chops the DC voltage andsupplies it to a transformer T′ on the side of a primary winding of thetransformer T′ (left side of transformer T′ in FIG. 3). The transformerT′ transforms the chopped primary voltage to a secondary voltage andsupplies it to a secondary winding of the transformer T′ (right side oftransformer T′ in FIG. 3). The secondary voltage is then rectified byrectifier diodes D3′, D4′ and supplied to the filter inductor 28. A setof diodes Dr, D2′ provides a free-wheeling path for the magnetizingcurrent stored in the transformer T′ to flow when the pair of switchesZ1′, Z2′ turns off, and thus resets the magnetic flux or energy storedin the transformer core. Further, when switches Z1′, Z2′ are turned off,the second inverter circuit 26 is disabled and the second invertercircuit 24 no longer contributes to the output current through thefilter inductor 28.

The combined rectified secondary voltage is supplied to the weldingpower supply output V_out and a welding current I_out is output from thecircuits 24, 26 through the filter inductor 28. In some embodiments, theinverter circuits 24, 26 can include additional components or circuits,such as capacitors, snubbers, voltage clamps, resonant “lossless”snubbers or clamps, gate drive circuits, pre-charge circuits,pre-regulator circuits, etc. In some embodiments, a single ground can beconfigured to support both inverter circuits 24, 26, and the output ofthe diodes D3, D4 of the first inverter circuit 24 would couple with theoutput of the diodes D3′, D4′ of the second inverter circuit 26 beforeentering the inductor 28.

As noted above, further advantages and details concerning the use ofinterleaved inverters in the power supply 10 can be found in U.S.Application No. 62/274,117, filed Dec. 31, 2015, and U.S. ApplicationNo. 62/286,764, filed Jan. 25, 2016, which are hereby incorporated byreference herein in their entirety.

FIG. 3 also shows the control circuit 90 according to an embodiment ofthe present disclosure. Although shown in FIG. 3 as two control circuits90, the control circuit 90 can be more or less than two control circuits90. Referring to FIG. 3, the control circuit 90 is configured to receivea feedback voltage from the output of the welding torch 14. The controlcircuit 90 is also configured to receive a feedback current from acurrent sensor 27, 27′ that measures the current flowing through theprimary winding N1, N1′ of the transformer T, T′. Although shownseparately from the control circuit 90, the current sensor 27, 27′ canbe part of the control circuit according to some embodiments. Thecontrol circuit 90 is further configured to provide an output signalthat turns the switches Z1, Z2, Z1′, Z2′ on or off based on the feedbackvoltage from the output of the welding torch 14 and the feedback currentfrom the current sensor. By turning the switches Z1, Z2, Z1′, Z2′ on oroff, the control circuit 90 can control or set the current that flowsthrough the primary winding N1, N1′, thereby controlling or setting theoutput current of the transformer T, T′, the inverters 24, 26, and thewelding torch 14 (e.g., the welding current).

In some embodiments, the control circuit 90 is not configured todirectly measure or sense the high output current of the welding torch14 using an expensive current sensor that is customized for highlyaccurate, high current measurements such as in welding operations. Thus,the control circuit 90 can avoid the use of costly current sensors suchas a high current Hall Effect sensing device.

The control circuit 90 and its operations are further discussed withrespect to FIG. 4 which shows an embodiment of the control circuit 90according to the present disclosure. Referring to FIG. 4, components ofan inverter of a welding power supply are shown including, for example,output studs 102, an output rectifier 103, a transformer 104, and aprimary switch 106. The control circuit 90 can include, for example, acontroller 100, a command potentiometer 101, a current sensor 105, and avoltage comparator 107. The controller 100 is connected to the output ofthe welding system (e.g., at the electrical circuit node of the outputstuds 102), the command potentiometer 101, the voltage comparator 107,and the primary switch 106.

The controller 100 can include, for example, a potentiometeranalog-to-digital converter (ADC) 108, a voltage feedback ADC 109, aprimary current reference digital-to-analog converter (DAC) 110, a pulsewidth modulated (PWM) timer 111, and a combiner 113. The potentiometerADC 108 is connected to the command potentiometer 101. The voltagefeedback ADC 109 is connected to the output of the welding system (e.g.,at the electrical circuit node of the output studs 102). Thepotentiometer ADC 108 and the voltage feedback ADC 109 are connected tothe combiner 113 which, in turn, is connected to the primary currentreference DAC 110. The primary current reference DAC 110 is connected tothe voltage comparator 107. The primary winding of the transformer 104is connected to the voltage comparator 107 via the current sensor 105(e.g., a primary current measuring device). The voltage comparator 107is connected to the PWM timer 111 which, in turn, is connected to theprimary switch 106.

In operation, the voltage at the welding system output is directlymeasured by the voltage feedback ADC 109 and converted into a firstdigital value. A current command signal is set up at the commandpotentiometer 101 and received and converted into a second digital valueby the potentiometer ADC 108. In some embodiments, the current commandsignal can be set up at an encoder or switch instead of the commandpotentiometer 101. The first digital value and the second digital valueare combined by the combiner 113. The combiner 113 is configured inhardware and/or software to calculate or determine a combiner output(e.g., a peak primary current reference) that is received the primarycurrent reference DAC 110. Thus, in some embodiments, the combiner 113uses the voltage or current command CMD from the command potentiometer101 and/or the voltage feedback VFB from the system output to determineor compute the peak primary current reference and to set an analogvoltage IREF that is proportional to a commanded reference current viathe primary current reference DAC 110.

In some embodiments, the combiner 113 is configured in hardware and/orsoftware to implement a transfer function. The combiner 113 can be partof an integrated circuit (e.g., application specific integrated circuit(ASIC), programmable gate array, etc.) and/or can be part of amicrocontroller, microprocessor, processor, etc. The transfer functioncan be, for example, a weighted combination of functions based on thefirst digital value and/or the second digital value. The transferfunction can also account for the turns ratio of the transformer, theaverage output voltage of the system, and other effects of a PWMtransfer function. The transfer function can also be configured forcurrent mode control (e.g., commanded peak current control). In someembodiments, the transfer function is multi-variable and can translatethe commanded primary transformer current to regulate the output currentof the welding system.

The voltage comparator 107 compares the reference current IREF from theprimary current reference DAC 110 and the current feedback IFB from thecurrent sensor 105. The comparison controls the PWM timer 111. The PWMtimer 111 provides a PWM signal with a 50% duty cycle, for example, thatcontrols the primary switch 106. The primary switch 106 can cause thetransformer 104 to turn on or off.

In some embodiments, in the beginning of the PWM cycle when the primaryswitch 106 turns on, the current increases in the transformer 104 andthe current sensor 105. The current sensor 105 sends a voltage signalIFB that is proportional to the current in the primary winding of thetransform 104 to one of the inputs of the voltage comparator 107. Oncethe voltage signal IFB increases to the level of voltage IREF at theother input to the voltage comparator 107, the voltage comparator 107changes state and sends a signal to the PWM timer 111, which turns offthe output of the PWM timer 111 and primary switch 106 for that cycle,thereby reducing the PWM duty cycle. While the primary switch 106 isoff, current decreases in the transformer 140. Once the PWM timer 111completes its PWM cycle, the process repeats itself.

In sum, some embodiments provide systems and methods that provide aconstant current controller for use in welding applications such asconstant current welding processes.

Some embodiments provide a control method in which the output current ofthe welding system is controlled and regulated by setting or controllingthe current in the primary winding of the main transformer of aninverter in the welding power supply.

Some embodiments provide an advantage in that the hardware is not usedto directly measure the output current of the welding system. Since theoutput current is typically much larger than a primary winding currentin a transformer of the inverter in the welding power supply, directcurrent measurements of the output current require very large andexpensive current transducers for feedback control. Such expensivecurrent transducers typically employ additional power supplies andcabling that further add to the cost of the system and prohibit themounting or integrating of the assembly on a printed circuit board.Instead, some embodiments use a very low cost current transformer as acurrent transducer for the current control by measuring the currentthrough the primary winding in a transformer of the inverter in thewelding power supply. Thus, some embodiments provide that currentcontrol is achieved without the expensive current sensor (e.g., a highcurrent Hall Effect current sensor) and without directly measuring theoutput current of the welding power supply.

Some embodiments contemplate using other types of current sensors formeasuring the current flowing through the primary winding of thetransformer such as less expensive versions of resistive shunt elementsor less costly versions of Hall Effect monitoring devices. Since theprimary winding currents being sensed or measured are much smallercompared to the output currents of the welding system, the currentsensors are generally cheaper and cheaper versions of resistive shuntelements and Hall Effect monitoring devices can be employed.

While the present methods, processes, and systems have been describedwith reference to certain implementations, it will be understood bythose skilled in the art that various changes may be made andequivalents may be substituted without departing from the scope of thepresent methods, processes, and systems. In addition, many modificationsmay be made to adapt a particular situation or material to the teachingsof the present disclosure without departing from its scope. Therefore,it is intended that the present methods, processes, and systems not belimited to the particular implementations disclosed, but that thepresent methods, processes, and systems will include all implementationsfalling within the scope of the appended claims.

What is claimed is:
 1. A welding system, comprising: a controller; and aprimary winding of a transformer that is operatively coupled to thecontroller, wherein the controller is configured to receive a feedbackvoltage from a welding output of the welding system; and a currentsensor configured to output a first signal representative of a primarycurrent in the primary winding of the transformer, wherein thecontroller is configured to control an output current at the weldingoutput of the welding system by controlling the primary current based ona comparison of: the first signal; and a second signal generated basedon a current command signal and the received feedback voltage.
 2. Thesystem according to claim 1, comprising: a voltage comparator having thefirst signal as a first input and the second signal as a second input.3. The system according to claim 2, wherein the voltage comparator isconfigured to compare the first signal and the second signal, andwherein the voltage comparator is configured to control the primarycurrent in the primary winding of the transformer based on thecomparison.
 4. The system according to claim 3, wherein the controlleris configured to control a pulse width modulated timer based on thecomparison, and wherein the pulse width modulated timer is configured tocontrol a switch that is operatively coupled to the primary winding ofthe transformer.